EP1581702A1

EP1581702A1 - Composite shaped block

Info

Publication number: EP1581702A1
Application number: EP03799445A
Authority: EP
Inventors: Thomas Sievers
Original assignee: Individual
Current assignee: Individual
Priority date: 2002-12-31
Filing date: 2003-12-25
Publication date: 2005-10-05
Also published as: WO2004061239A1; AU2003299276A1; DE10261692A1; US20060251862A1; RU2005124031A; CN1745218A; JP2006512519A

Abstract

The invention relates to a composite shaped block produced by placing a top plate serving as a covering layer onto a supporting body. This supporting body is provided with a binder compound and is produced by a shaping process. The invention also relates to a method for producing composite shaped blocks of this type.

Description

Nerbundformstein

The invention relates to a Nerbundformstein produced by applying a top plate as a cover layer on a support body provided with a binder, produced by a molding process and a method for producing such Nerbundformstein.

Shaped stones and in particular paving stones / paving elements, terrace and sidewalk slabs are known in many different forms. They are used for the design of gardens, as well as for the attachment of walkable and passable areas.

Natural stones are unique optical pieces with a long lifespan and high prestige, features that cannot be achieved with industrially manufactured concrete or artificial stone in the surface. The advantages of a natural stone are the high aesthetic value, the great variety of materials and the rich selection of colors, structures and quality. As a result, more and more architects, planners and builders see themselves forced to use natural stone products, even if they are much more expensive. However, paving natural stone as a floor has the disadvantage, in some cases, of using poorer usable areas with less resilience than concrete or cast stone. In addition, laying can often only be carried out by specialists and not by machine. The following can therefore be mentioned as disadvantages: the high material and labor costs, and the often lacking craftsmanship to process the natural stone properly.

Concrete stones are made from cement, quartz sand and aggregates. They are manufactured industrially and can be produced inexpensively and in large quantities and with low manufacturing tolerances in any desired form. They have the advantage over sawn, smooth-walled natural stones that the flank surfaces (side surfaces) and the laying side (foot side) are rough due to production, which results in a better "claw" in the laying bed and in the availability. You can do this by changing the material thickness and joint geometry Concrete or concrete building blocks can be laid easily and quickly by machine or by assistants and do-it-yourselfers. In contrast to natural stone products, the above-mentioned properties enable inexpensive, optimal technical usable areas to be produced even for the highest loads. It is disadvantageous, however, that the desired natural stone appearance is usually only insufficiently achieved by structuring and coloring the concrete or cast stone surfaces. In contrast to natural stone products, the surfaces usually become dirty very quickly or at least faster and, depending on their use, therefore often have a significantly shorter lifespan of only about 10 to 15 years.

These structured concrete parts, e.g. with imitated granite surfaces, ground or available with a rough surface in different plate, cuboid or column formats in the building trade. Their appearance is significantly influenced by the additives used, but also by any surface treatment. However, natural stones embedded in molded concrete bodies are also known, e.g. from EP 0 566 084-A1.

EP 0 717 147-A1 describes a composite stone made of concrete element with a trough-shaped recess and a natural stone slab with a stepped underside. The section of the stepped underside protruding over the edge engages in the trough-shaped recess. It is disadvantageous that the natural stone slab has to be milled out or exposed to another material-removing processing step. Such processing steps cannot be carried out with the required precision, which on the other hand makes it necessary to overdose the amount of adhesive because this cannot be determined exactly. Excess adhesive slows down the setting process and, above all, complicates the exact positioning of the natural stone slab relative to the concrete element.

Natural stones have a different thermal expansion and water absorption capacity than concrete. When installed outdoors, these materials are exposed to extreme weather conditions such as high temperature differences, frost / thaw cycles and permanent wetness for decades. Consequently, the adhesive layer of a composite material, such as a composite material made of natural stone and concrete, must be able to permanently compensate for the elastic, tensile, shear and compressive forces resulting from the different expansion coefficients of the two materials and the mechanical loads. Furthermore, the adhesive layer must not swell or lose its adhesiveness due to permanent moisture or wetness, in order to guarantee a permanent connection of even the most diverse materials over decades. The present invention has set itself the task of using the advantages of a concrete material and at the same time eliminating their disadvantages, but in particular to provide shaped stones with top surfaces of high aesthetic value in a rich variety of colors and structures.

This object is achieved by the composite molded block according to claim 1. Advantageous developments and embodiments of the invention are possible through the measures mentioned in the subclaims.

The invention relates to a composite molded block produced by applying a top plate as a cover layer to a support body provided with a binder compound and produced by a molding process. The top plate and the support body are provided over the top surface of the support body and are permanently bonded to a paste-like and solidified, preferably mineral-containing binder, the

Head surface of the support body for optimal absorption of the binder, preferably has a circumferential edge and the head surface is additionally structured in a defined manner.

The top plate is preferably 0.5 to 3 cm thick. The top and bottom surfaces of the top plate are preferably made plane-parallel over the entire surface.

The support body preferably has a thickness of 2 to 16 cm, but can also be up to 20 cm thick, for example, and can be produced in a wide variety of volume dimensions, but preferably has an essentially cuboid shape, with head and

Base surface of the support body preferably form substantially plane-parallel surfaces. The side surfaces are preferably oriented approximately perpendicular to the head surface.

The binder mass forms an intermediate layer which is essentially externally delimited on all sides by the support body and the top plate.

The side surfaces of the composite molded block according to the invention can have cams (bulges) and additionally recesses, in particular in the region of the support body, so that the cams of a composite molded block when laid in

Engage the composite in corresponding recesses in adjacent composite form systems as side teeth. Are corresponding recesses to the If there is no intervention, the cams act as a spacer when laying in a network and as a transport lock.

According to a further embodiment of the invention, the support body has cams on all corners, which provide additional support on the structurally weakest

Form the top plate (corner). The cams preferably have a semicircular shape when viewed from above, act as a spacer in combination to form a uniform joint pattern and protect the corners.

The side toothing can form positive connections in connection with the aforementioned "corner formations", which are made over a large area or by means of interlocking toothing elements, for example in the form of form-fitting interlocking spacers on the side walls. The spacers can provide spaces or joints between the laid paving stones be created that secure wedging or interlocking between the

Allow stones and better drainage of the installed area.

The cams and the additional recesses also make it easier to lay them together, ensure even spacing between the joints, durable availability and additional stability in the pavement. The high resistance to twisting / tilting is particularly advantageous in traffic areas with high horizontal loads (inclines or the like).

The toothing ensures a better overall connection of the installed surface compared to materials where no toothing is provided. The toothing is preferably designed in such a way that at the same time this results in the distance for the subsequent joint of the laid surface and also acts as a transport lock.

The cams can be made over the entire height of the support body, if necessary they even extend over the total height of the support body in the direction of the

Upper plate, for example 1 to 6 mm, preferably 2 to 4 mm, above the total height of the support body, and then preferably serve as a lateral stop and for centering the upper plate. The part protruding above the total height is preferably beveled, preferably at an angle of 40 to 60 degrees, so that it is not visible in the joint pattern. The spacer has an angular shape in this part which is raised above the bearing surface, the shorter leg of the angular shape preferably lying flat against the top plate. The support body preferably has spacers (cams) on the side surfaces. These spacers are arranged vertically at various points on the outer surface so that the composite blocks can be laid in different formations (such as a runner, cross or herringbone form). The spacers are designed depending on the dimensions of the composite molded block, its height and the intended use in different thickness, width and shape. The spacers prevent the top plates from bumping against each other, both during transport and during installation, and ensure that a minimum joint dimension is maintained and that the joints are properly filled when installed. The spacers / cams can also be designed so that they are provided with a predetermined breaking point. This ensures that the desired joint width is created during installation, but at the same time prevents concrete from bumping into concrete. Rather, the spacers break when loads occur at the predetermined breaking point and the joint filling material takes over the functions of the power transmission and the buffering effect, as designed.

The support body forms the lower base layer of the composite block in the position of use. The support body is preferably made of concrete, but can be made of other suitable materials, such as plastic, metal, wood, clay / ceramic or hybrid mixtures or sandwich construction.

The support body gives the top plate the required resistance to breakage and use, in particular compressive and bending tensile strength, and is preferably selected so that its material value is significantly less expensive than the top plate material. The support body is made from a pourable, pourable, or free-flowing material through a molding process.

The support body can be shaped so that several support bodies or composite molded blocks can be stacked one inside the other, which saves transport and storage costs. The support body can also be provided with cavities in which supply lines, lighting elements / lighting bodies and heat transfer media can also be accommodated, if necessary.

The support body can be cut to the desired final thickness on the foot side by sawing, calibrating or other processing. Under- Different thicknesses of the support body can arise if the top plates have different thicknesses.

It is also possible to reinforce the support body on the foot side in a final step in order to produce the required constant overall height with different top plate thicknesses, for example by applying another layer of concrete.

However, the support body can also be made from plastic material, in particular from recycled plastic waste material. The walkable and passable

Composite molded block consisting of a plastic layer, intermediate layer and mineral top plate is then, despite essentially the same technical values in terms of compressive strength and bending tensile strength, many times lighter than conventional mineral molded bodies.

The plastic material used can be made from mixed plastic fractions which are either pre-pelleted as so-called pellets for further processing or mixed via a so-called impact reactor or otherwise prepared for injection molding. The core can also be made from sorted or unsorted plastic waste. The different geometric shapes of the

Support bodies can be manufactured using "simple" and inexpensive injection molds, which additionally makes the shape overall less expensive than coverings made of natural stone.

To increase overall stability, an appropriate contrasting shape can be inserted into the base of the plastic support body in order to achieve a closed installation surface. This contrasting form can be produced in a force-fitting manner in such a way that an airtight space is created which provides an insulation effect which, in the event of suitable weather, reduces the formation of frost on the top of the plate and thus, among other things, the risk of accidents.

Cavities in the support body can be heated by suitable measures; for this purpose it is possible to provide the opposing shape with heating wires, for example, or to heat it up differently; the necessary energy can be supplied using suitable plug-in systems that are connected to each other; the coverings can thus be heated cheaply and effectively. A lighting device can be introduced into the plastic core and the core itself and the o Mineral material top plates can be designed so that they are translucent.

The geometric shape of the plastic core makes it possible to minimize the thermal expansion of the plastic core.

The finished covering has significant advantages over conventional coverings for larger installation heights (from 3 cm) in that it is lighter and sawing and drilling and other machining operations are easier and less costly to carry out. Furthermore, it conveys a more pleasant feeling of walking compared to coverings made exclusively from mineral materials.

Concrete is made from a mixture of cement, aggregates - also known as concrete aggregate - and water as well as any additives by hardening the "cement paste" (= cement + water). As "fresh concrete" with selectable

In the consistency area, the concrete can be poured into any shape and structure or shaken / pressed. After hardening, the support body usually has a compressive strength of 25 N / mm to well over 60 N / mm ² .

Mixtures of unbroken and / or broken are used as aggregates

Grains made from natural and / or artificial mineral substances are used, e.g. Different sized grains of sand, gravel, grit, gravel, expanded clay or expanded slate (light concrete), slags and / or iron oxide.

Common additives such as plasticizers, air entraining agents,

(Color) pigments; Concrete sealants, solidification accelerators, solidification retarders; Stabilizers, plasticizers, plasticizers, press-in aids, micro- and nanosilica, rock flour, plastic dispersions, fibers and / or chromate reducers can be added.

If cement and water are mixed into a paste, it gradually becomes solid. The cement paste develops through hardening (solidification) and hardening to cement stone. This consolidation is based on the formation of water-resistant (hydraulic) connections.

There are various options for compacting the concrete: for example, reinforced pounding, poking and shaking. The support body can also be made of reinforced concrete exist, ie reinforcement inserts (round steel, steel mesh, fibers, nonwovens etc.). While the concrete has the compressive strength, the tensile steel or the other components mentioned take over the tensile stresses that occur.

Concrete changes its volume due to creeping, shrinking and especially due to the different seasonal influences. For every 100 K temperature difference, a 10 m long component changes e.g. about 10 mm in length. This also creates tensile and compressive stresses.

The support body has an upper support surface which is designed to be essentially plane-parallel to the foot surface. The contact surface is designed as a structured three-dimensional surface. The structure can be of different shapes. Common to all surface structures is that they have an outer raised edge along the side edges of the support body and the upper edge forms a support surface that is essentially plane-parallel to the foot surface.

In addition, there are preferably a plurality of raised support surfaces as additional support supports in the area spanned by the outer edge. The upper edge and the raised partial contact surfaces preferably form a jointly, possibly common, supporting surface. For this purpose, the inner raised partial contact surfaces may be slightly higher than the edge contact surfaces, possibly lower, preferably of the same height. The partial contact surfaces can have a pyramid, hemisphere or cone shape or, less preferably, be designed as undulating, zigzag and or groove-shaped elevations. The partial support surfaces form fixing points for the top plate to be applied and prevent the top plates from tilting or shifting sideways or vertically. The actual contact surface of the partial contact surfaces preferably has an area of

0 0 0 less than 2 cm, in particular less than 1 cm or even less than 0.5 cm. Bounded by the edge, there can be at least 4, preferably over 12 partial contact surfaces distributed over the trough-shaped recess. The contact surface is to be understood as the surface in contact with the top plate, including any binder material between the top plate and the contact surface with a thickness of up to three times the average grain size of the binder material.

The defined contoured surface structure results in a predictable

Recess volume and an enlarged surface for the gluing / connection with the top plate and a higher shear, due to the inner contact surfaces Bending tension and pressure stability in order to absorb the forces that arise during driving and to take the different expansion coefficients of the materials used into account as well as possible.

The height of the partial contact surfaces and their geometry allow the adhesive volume to be applied to be calculated and prevent excess binding compound, so that it does not escape undefined on the side surfaces if the top plate is placed on the top surface of the upper body and there is still an even distribution in the trough-shaped recess , and when applying the binder, the partial support surfaces are to be provided with binder.

In addition, the small contact area and the large number of contact areas deliberately accelerate the setting process of the binder mass at the tips of the partial contact surfaces, which ensures that the applied top plate is immediately fixed. This ensures that the composite stone in the manufacturing process can be transported and further processed immediately after the top plates have been applied, without the top plates shifting from the defined location in the further work process or detaching from the composite.

In contrast to the previously known methods, the aforementioned features provide the possibility of producing a composite molded block in an industrial manner in the timed production process and also to calculate the volume of the adhesive to be applied exactly. The partial contact surfaces also allow the composite blocks to be stacked without the binder mass having to be fully hardened.

According to a further embodiment, the circumferential outer edge can also be perforated in order to deliver binder mass at a defined location. The breakthroughs can have passages in the size of 0.2 to 1 cm. The support body preferably has only 1 to 6, in particular 1 to 3, openings per side surface of the support body.

The partial contact surfaces can also be subsequently applied to the surface outside the manufacturing process of the contact body or introduced into the contact body, which have the same geometries as described above. The layer thickness of the binder composition is preferably on average 2 to 12 mm, particularly preferably 2 to 5 mm.

It is also possible to provide the supporting body, starting from the head surface with further extending in the direction of the root surface cavities, preferably to a depth of 2/3 of the total thickness of the support body, ^'. The cavities serve to save material and weight and continue to absorb excess binder, which has a positive influence on the adhesive bond. The total volume of all depressions / cavities can thus make up 5 to 75 volume% of the total volume of the support body.

The further cavities extending in the direction of the foot surface can be shaped in such a way that they widen downward in diameter so that the binder mass penetrates from above, forms a pasty downward formation and thus wedges after hardening.

Cavities in the form of troughs are also particularly preferably introduced into the trough-shaped depression. The volume of the troughs can e.g. equal to 50%, preferably 5 to 15%, less than the volume of the partial contact surfaces,

It is further preferred that the troughs are distributed in the same grid as that of the elevation, i.e. each partial contact surface has on average at least 1 half trough adjacent in order to provide a short path for the binding compound when the top plate is put on. The adjacent trough preferably has 0.2 to 1 times the volume of the partial contact surface.

Preferably, the cavities, in particular the cavities extending from the head surface in the direction of the foot surface, are not completely filled with binder compound, so that cavities remain which serve as a buffer against thermal expansion.

In the process of manufacturing the support body, the surface geometry of the support surface of the support body, including the cavities extending in the direction of the foot surface, can be expressed in a simple manner by the type of the upper punch; if necessary, two upper punches are used, one for introducing the

Cavities extending in the direction of the foot surface and one preferably downstream for the formation of the structured contact surface. The one with more In contrast to the solid body, the support body provided with cavities has a weight and material saving. Such a support body can also be used as a paving stone.

The top plate as the top layer can consist of porcelain stoneware, ceramic and / or natural stone as well as other materials such as glass, wood, rubber, metal etc. It preferably has a cuboid shape.

The upper plate, in particular made of molded materials, can have different geometric shapes on the foot head side for interlocking with the binder and the support body, the foot side preferably being planar and possibly having a certain roughness.

The connection surface can also be machined by mechanical thawing such as faltering, blasting, scratching, milling, planing etc. in order to achieve an enlarged adhesive surface.

Natural stones are natural stones from various basic components, e.g. B. limestone, dolomite, sandstone etc. Below are some suitable natural stone materials: volcanic stones such as granite, syenite, diorite, gabbro,

Basalt, diabase, rhyolite, trachyte, sedimentite such as psephite, conglomerate, breccia, sandstone including limestone, slate, travertine, dolomite stone and shell limestone, as well as metamorphite such as orthogneiss, quartzite, mica schist, phyllite and paragneiss.

Granite is one of the best known and most important deep rocks and consists of feldspar, quartz (20-40 / 50%) and mica (0-10%). Mica gives the granite the contrast and ensures that the stone can be split; Feldspar and especially quartz give the hardness, the feldspar content determines the color of the rock.

"DiamondQuartzite" is a fissile material that is available to over 80% in layer thicknesses between 1.0 and 2.0 cm and whose rich occurrence can be mined in open-cast mining. Quartzite belongs to the natural stone group with the highest degree of hardness. The natural layer thickness and roughness of the Quartzite surfaces do not require any further processing to produce the composite stones according to the invention. Only the usual material cutting has to be carried out. The surface roughness on the one hand fulfills all the requirements for permanent wear. bond and on the other hand a permanently non-slip, wear-resistant floor covering surface.

Other natural stone deposits with a hardness similar to e.g. Granites can only be mined in block form. Granites have to be sawed into slabs with diamond or gang saws and both surfaces have to be mechanically reworked for use as top slabs.

The top plate preferably has the following length (longest side) to thickness expansion: greater than 3 to 1, in particular greater than 5: 1. The plate can be produced by splitting or machining, such as sawing.

Porcelain stoneware is a sintered, artificially produced ceramic product. It is very compact and also has a very low porosity, which gives it special mechanical and chemical properties, such as

Frost resistance, i.e. a product that can be used well in cold climates for outdoor wall and floor coverings. The porcelain stoneware is also very resistant to chemicals and cleaning agents, has a very high abrasion resistance and a high degree of breaking strength. This makes it ideal for areas with intensive public traffic and in industrial plants. Add to that the easy cleaning.

The search for new manifestations has led to a number of treatments for the final product, such as polishing, which created two different types: natural and polished porcelain stoneware. The natural one

(does not receive any after-treatment after firing) has a natural appearance and partly imitates. even stones that can be found in nature, such as slate, marble, paving stones, etc. With polished porcelain stoneware, the material is polished after firing, which gives it a strong shine and imitates the surface appearance of polished marble.

The top plate can be surface-finished using the method described in European Patent EP 1 124 774 and EP 0 825 917-B1 (corresponds to US Pat. No. 6,167,879). The disclosure content of these protective rights is hereby also made the subject of this application by reference. The special surface treatment of the top side of the top plate, which includes a laser treatment and, if necessary, in combination with a subsequent impregnation treatment, or only an impregnation treatment, creates a dirt-repellent and non-slip surface that can be used in many ways as floor and stair covering. The surface treatment can be used particularly preferably on natural stone surfaces.

In addition to water and aggregates, the binder contains at least one binder. The binder is preferably an aqueous polymer dispersion, optionally used together with a cement binder. The binder hardens through contact with moisture.

The main constituent by weight of the binder mass after drying is aggregates, for example fine sand, in particular quartz sand with a grain size of 0 to 2 mm, in particular 0 to 0.1 mm. A cement, for example Z325, is also advantageous

Portland cement, mixed.

The binder composition is applied to the head side of the support body, preferably flat or in the form of pasty, in particular pasty, flat strands, in particular over the entire width of the support surface or defined points, the head side of the support body having partial support surfaces and the storage surfaces for the binder composition be limited by the outer partial contact surfaces. The upper partial contact surfaces adjoining the side surfaces of the support body can also be coated with binder, e.g. Adhesive mortar. The exact calculation of the volume of the binder mass as well as the outer partial contact surfaces prevents / reduces or defines where the perforations are present, so that the applied binder mass cannot escape when the top plate is placed on the support body. Relative to the hollow space formed between the outer partial support surface and the plane-parallel end surface of this edge support

Internal volume is preferably applied at least as much volume of binder mass as corresponds to the upper cavity interior volume (except for the cavities that may extend in the direction of the foot surface), in order to ensure that a full-surface adhesive connection is formed with the exclusion of cavities. Depending on the material of the support body, the binder can also consist of acrylate, one- and two-component polyurethane, thermoplastic, duoplast or epoxy compounds, which can also be reactive, for example.

The aqueous polymer dispersion is suspended / dispersed in water and preferably a polymer which, in addition to styrene and / or butadiene units, has at least one polar monomer or polar groups, such as e.g. Carboxyl groups e.g. in the form of acrylate, methacrylate or vinyl acetate groups / monomers. For resistance to hydrolysis, it is important that the polymer has a carbon chain as the backbone (carbon backbone) that bears polar side groups.

Suitable are, for example, vinyl acetate polymers in aqueous dispersion, carboxylated butadiene-styrene-mefhaacrylate polymer latices or polyurethane dispersion.

The composite molded block can have the shapes customary in the prior art, such as cube, binder or one and a half shape, double stone, prism stone, head or bishop's cap shape. The composite molded block according to the invention is preferably used as a paving element for outdoor facilities such as walkways and driveways and terraces and as a raised floor system for indoor areas, but it can also be used with its described advantages as a facade element.

As a paving element for outdoor facilities such as sidewalks and driveways, it is laid as a paving slab on a bed, preferably by means of a joint filling. In addition to conventional mineral fillers, jointing compounds which contain cement, bitumen as binders and / or additives of plastic binders can also be used as jointing compounds.

Due to the geometry of the paving stones, the stones are bonded to one another and the detachment of individual stones by the action of traffic loads and forces is avoided. The composite molded bricks according to the invention can be laid, for example, in a row, herringbone or Keper bandage, scale arches, diagonal bandage, block or parquet bandage, cross joint bandage, runner bandage or in the Roman bandage.

In contrast to natural stone paving, the composite molded block according to the invention can be placed on a prepared paving bed and does not require a bed. in which it is aligned with a paving hammer to correct the flatness.

The composite molded bricks according to the invention can also be used as walkable and drivable exterior covering material for the highest surface loads and represent a product that can be laid as easily as a concrete or cast stone. The covering is easy to install even by inexperienced do-it-yourselfers

The composite stone can also be used as a replacement, e.g. indoors and outdoors. used for stone slabs. The overall thickness can be between 2 and 7 cm, depending on the use, the top plate preferably having a thickness of less than 1.3 cm.

The composite stone slab can also be produced for indoor areas or for the use of terrace slabs etc. in total thicknesses below 3 cm, e.g. to be equipped with a top plate made of porcelain stoneware, which as a solid material cannot currently be manufactured in thicknesses over 1.5 cm or only with great technical and cost expenditure.

The invention is also based on the object of providing an industrial, clocked mechanical method for producing the composite molded bricks according to the invention. This object is achieved according to the invention by the method features characterized in claim 21. Preferred embodiments are the subject of claims 22 to 27.

On a vibrating table, a defined volume of concrete is poured into a mold frame, which corresponds to the support body to be produced, and compacted by vibrating and shaped with a stamp in relation to the top surface.

The vibrating forces can be applied in a manner known per se in concrete block molding machines, ie by vibrating the mold and / or the stamp, but preferably by vibrating the vibrating table and / or by vibrating a stamp load. The molded block can also be compacted in a manner customary in the industry by pressing or stamping. The support body, here the support surface for the top plate, is preferably moistened with water before the binder is applied. A polymer, as defined above (with aqueous polymer dispersion), can be added to the water in a weight ratio of 1: 9 to 1:50 to improve the adhesive effect as an adhesion promoter. The application is preferably carried out by means of a metering device in the spray process.

The stamp contours the head surface of the support body and, in particular, embosses the peripheral edge and the partial support surfaces through depressions in the stamp, which serves as the support surface for the top plate. If desired, the further cavities (troughs) extending in the direction of the foot surface are also introduced by the same or a further stamp. For this purpose, preferably finger-shaped, cylindrical or tapered pins are mounted on the stamp surface and inserted into the concrete mass when the stamp is lowered. These are preferably aligned in the direction of the surface normal of the stamp surface.

The molding can be done by raising the mold frame and / or the stamp. After the stamping process or after a number of stamping processes, adhering concrete residues can be removed from the stamp surface.

The shaped and dimensionally stable support body is coated on the surface with the pasty binder, preferably by means of metering nozzles, under which the support body is moved with the head surface facing upwards. The binder mass is spread over the top surface of the support body, preferably under

Omission of the peripheral edge, laid, in particular in a substantially uniform layer thickness, preferably between 2 and 5 mm, the application height of the binder composition being the height of the partial support surfaces of the head surface of the support body, independently preferred, by no more than about 0.5 mm - he walks.

Before applying the binder, it may be advantageous to moisten the support body in order to positively support the subsequent step of bonding. For this purpose, the spray water can be mixed with the polymer of the adhesive connector, preferably in a ratio of 20 (water) to 1 (polymer). The binder consists of various mineral substances (quartz sand, cement) as well as mixing water and a polymer additive, which are mixed with one another in a so-called compulsory mixer before being applied to the support body and then moved from the mixing container into a storage container with a slow-moving agitator for further processing , When transporting the mixed binder, it must not be stimulated by pressing or pressure to separate the solids and liquids. This is guaranteed by the combination of suitable pumps in connection with transport pipes dimensioned accordingly in volume.

The top plate and the support body are then lowered flush with one another on the side surfaces, the approach preferably taking place with slight rotation about the approach axis, possibly also with a slight vibration movement along (perpendicular) the approach axis. To bring the top plate and the support body together, the support body is preferably conveyed in a cyclical fashion. The head surface of the support body preferably slightly exceeds the foot surface of the top plate, approximately on average on all sides by 0.5 to 2 mm.

The top plate can be centered with the support surface by measuring the support body beforehand and positioning it accordingly using the transmitted data.

The top plate can be guided by a gripper, in particular a suction head gripper. The subsequent fixation or pressing of the top plate can be done by stationary roller elements or carried pressure elements. For quick hardening, the composite stone can subsequently be subjected to a thermal treatment. This is preferably done by moving the composite molded block in a room tempered to 90 to 150 ° C, ideally 110 to 130 ° C, e.g. a "Patanosta" or a "tying tunnel".

If desired, the top plate can be provided with an impregnating agent that is usually in the strongly structured surface penetrates well. For this purpose, the impregnating agent is sprayed onto the surface of the top plate before entering the drying tunnel.

To support this, the top plates can be heated to approx. 30 ° C to 45 ° C before application to the support body, which also means additional advantages. le can result in the adhesive connection and to improve the subsequent impregnation effect, since the impregnation active ingredient is absorbed much better in a tempered surface. The heating can take place, for example, in a stack / storage device upstream of the application of the top plate to the support body.

An aqueous dispersion of an organosilicon compound in water is particularly preferred as the impregnator. Such a composition can also be an additional dispersing aid. The organosilicon compound can, however, also be taken up in a hydrocarbon medium such as white spirit. A particularly advantageous impregnating agent has proven to be a dispersion of an alkylalkoxysilane and a fluoropolymer in water.

However, the impregnating active ingredient can also consist of an aqueous dispersion of an acrylate copolymer. The impregnator is preferably applied by means of a metering device and a surface application of the impregnator / impregnating composition, preferably by spraying, but the application can also be carried out by other methods such as e.g. roll up.

After the impregnator has been applied, treatment with thermal heat, microwaves, UV or IR radiation can also be carried out, recrystallization of the surface either at mild temperatures or fusing of the organosilicon compound with the carrier material at high temperatures. According to a preferred embodiment of the invention, a limit temperature of e.g. Do not exceed 75 ° C on the surface of the mineral material. The process described above can be repeated several times, e.g. a second or third impregnation of the surface of the top plate takes place at the exit of the so-called “drying tunnel”.

Through an attachment as a contact surface of the concrete core, e.g. Using natural stone chippings, an increased adhesive and shear effect can be achieved and a defined surface geometry can be created. This layer can be tempered by additives, e.g. Water permeability must be equipped to ensure that the surfaces dry quickly (after laying and when wet) and to prevent moisture from the concrete core in or through the adhesive layer or

Surface penetrates or reaches. An advantage over the full natural stone is the possibility of simple shaping of the concrete cores - oval, round, angular, also with cuts, all common geometric shapes are cost-effective or possible at all in contrast to the full natural stone. At the moment, geometrical shapes outside of the shaping, which are possible with saw blades (straight cuts), can only be produced by means of elaborate water jet cutting and only to a depth of approx. 3 to 5 cm (depending on the stone) or by stone masonry. According to the invention, the top plates can usually only be 1 to 2 cm thick and the support body (concrete core) can be produced cost-effectively in any shape and height by shaping.

It is also possible to equip the composite stone as a drainage stone. A water-draining wear layer can be created by introducing cone-shaped cavities in the support body as well as corresponding passages (openings) that can be made to fit into the top plates.

In addition, it is possible to provide the top panels with luminous or display bodies, for example with fiber optic cables.

According to a preferred production variant, the support body is finally produced from “finer” facing concrete in order to obtain a surface that is more precise in shape than conventional concrete surfaces. In the core, an “upper concrete” is applied as the top layer, which can offer various advantages. The top layer can be equipped in such a way that the adhesive connection improves (system in system solution), it can be made impermeable to water (faster drying, prevention of water stains, faster defrosting in ice and snow), it can be designed more precisely, e.g. to be able to design the troughs or elevations better than conventional concrete. Small troughs on the highest points of the elevations can ensure that the binding mass forms a maximum thin layer there, so that the

Claws are used to absorb lateral forces immediately after joining. This makes it possible to stack the composite elements immediately after joining, without the cover or top plates shifting.

The invention is illustrated by the figures:

Figure 1 shows a plan view of the top surface of the support body FIG. 2 shows the composite molded block with support body and top plate along the section A through FIG. 1, the cavities (16) lying in plane B also being shown in FIG. 2 for the sake of simplicity. FIG. 1 is a top view of the area shown as C in FIG. 2.

The support body (3) has a peripheral edge (11) on the side surfaces (9) of the support body (3). The edge (11) forms a tub shape on the top surface (4). The upper edge of the edge (11) is designed as an edge surface (12) to the foot surface (8) of the support body (3) as a plane-parallel surface, the plurality of punctiform partial support surfaces (14) together with the edge surface (12) for the support surface (13) forms the foot surface (7) of the top plate (6).

The punctiform partial contact surfaces (14) are part of the pyramid structure formed on the top surface (4). Instead of a pyramid structure there are also others

Structuring / contouring such as troughs or zigzag walls possible. The pasty binder mass is deposited in the cavities (17), after the form-fitting attachment of the top plate (2) by the force of force being pressed into the remaining volume of the upper cavities (17) and essentially completely filling them. The cavities (16) extending in the direction of the foot surface (7) only partially absorb binder mass and serve, inter alia, as a volume buffer for the binder mass.

A cam (18) is shown as an example on the side wall of the composite stone, the length of which exceeds the height of the side surface (9) of the support body, which

However, the height of the side wall (10) of the composite molded block falls below and abuts the top plate (2) with the length protruding beyond the support body. The tip of the cam is beveled outwards at a 45 ° angle. This is a special embodiment, usually. such a supernatant is not necessary.

Claims

claims

1. Composite molded block (1) having an upper plate (2) as a cover layer and a support body (3) with a head surface (4) produced by a shaping process, whether egg

- The top plate (2) and the support body (3) via the head surface (4) of the support body are permanently connected,

- The support body (3) on the head surface (4) is provided with an applied and solidified binder and - The head surface (4) of the support body (3) trough-shaped for receiving the

Binder mass is pronounced.

2. composite molded block according to claim 1, characterized gekennzei chnet that s the top plate (2) has a thickness of 0.5 to 3 cm and independently of this the foot surface (7) of the top plate (2) forms a planar surface and in particular head ( 6) and foot surface (7) of the top plate (2) form an essentially plane-parallel surface.

3. Composite stone according to at least one of the preceding claims, thereby characterized, that the trough-shaped pronounced head surface (4) of the support body (3) in the area spanned by the outer edge (11) has a plurality of raised partial support surfaces (14) Has support supports.

4. composite molded block according to at least one of the preceding claims, d a - characterized in that s the trough-shaped pronounced head surface (4)

Partial bearing surfaces (14) with wings parallel to the foot surface (7) of the top plate aligned plane.

5. Composite shaped block according to at least one of the preceding claims, d a- by gekennz ei chnet that s the trough-shaped pronounced head surface (4)

Part support surfaces (14) formed according to one or more of the three alternatives mentioned below:

Part contact surfaces (14) are approximately the same height as the edge contact surface (15), partial contact surfaces (14) are preferably a maximum of 6 mm, in particular a maximum of 2 mm higher than the edge contact surface (15),

Part contact surfaces (14) are a maximum of 2 mm lower than the edge contact surfaces (15) having.

6. composite molded block according to at least one of the preceding claims, characterized g ekennz ei chn et that s the trough-shaped pronounced head surface (4)

Has 5 part bearing surfaces (14), at least 4 of the part bearing surfaces (14) keeping at least a distance from one another which is greater than 1/3 of the longest edge distance and at least each of the 4 partial bearing surfaces (14) being equal in one of four respectively connected partial surfaces The size of the trough surface is, with each of the 4 partial support surfaces (14) preferably being at a distance of at most 1/3 of the longitudinal edge distance from the edge (11).

7. composite shaped block according to at least one of the preceding claims, characterized gekenn ei chnet that s the foot surface (7) of the top plate (2) is smaller in area than the top surface (4) of the support body (3).

15

8. Composite stone according to at least one of the preceding claims, characterized by the fact that the support body (3) has a thickness of 2 to 20 cm and, independently of this, the head (4) and foot surface (8) of the support body have essentially plane-parallel surfaces form.

20

9. Composite molded block according to at least one of the preceding claims, characterized in that the hardened binder mass forms an intermediate layer between the support body (3) and the top plate (2), which on the outside essentially on all sides through the support body (3) and the top plate (2) limited

25 is.

10. Composite molded block according to at least one of the preceding claims, which have adjacent side walls (10) of the composite molded block in the region of the corners of the support body, cams (18),

30 of the side walls (10) in their extent at least by the length of the

Projection of the top plate (2) are spaced in the corner to serve the top plate (2) as a further contact surface and / or impact protection and the cams (18) preferably by an average of a maximum of 5 mm, preferably a maximum of 3 mm, in relation to the Stand the surface normal on the side wall (10).

35

11. Composite molded block according to at least one of the preceding claims, characterized by the fact that the side walls (10) of the composite molded stone, preferably in the area of the support body (3) have cams (18) or spacers and, if necessary, additional recesses.

12. Composite molded block according to at least one of the preceding claims, characterized in that the support body (3) forms the lower base layer of the composite molded block (1) in the position of use.

13. Composite stone according to at least one of the preceding claims, characterized in that the support body (3) is made of a flowable, pourable or flowable material by a molding process and the material made of plastic, concrete, metal, wood, clay / ceramic or their mixtures, preferably concrete.

14. Composite molded block according to at least one of the preceding claims, characterized in that the head surface (4) of the support body is designed as a structured three-dimensional surface in order to form a support surface (13) for the top plate (2), the head surface ( 6) has a raised edge (11) which runs around the outside along the upper edge of the side surface (9) of the support body in order to form one or more trays, in the case of inside edges, for receiving the binder mass (4), and the upper edge surface

(12) forms a support surface (13) which is essentially plane-parallel to the base surface (8).

15. Composite stone according to at least one of the preceding claims, characterized by the fact that the head surface (4) spans a surface within the circumferential raised edge (11), which has a plurality of inner, possibly also punctiform, partial bearing surfaces (14) for the Has top plate (2), the partial contact surfaces (14) not being higher than the edge contact surfaces (15), preferably of the same height.

16. Composite stone according to at least one of the preceding claims, characterized by the fact that the support body (3), starting from the head surface (4) with further cavities (16) extending in the direction of the foot surface, preferably to a depth of 2 / 3 of the total thickness of the support body (3) is provided, the total volume of all being independent of this

Wells / cavities (16, 17) preferably make up 5 to 75 volumes and% of the total volume of the support body (3).

17. Composite stone according to at least one of the preceding claims, characterized in that the top plate (2) consists of porcelain stoneware, ceramic, materials such as glass, wood, metal, rubber etc. and / or natural stone.

18. Composite molded block according to at least one of the preceding claims, characterized in that the binder (5) contains at least one binder in addition to water and aggregates, the at least one binder being an aqueous polymer dispersion, preferably using styrene and / or Butadiene units is produced as monomers and has a polar monomer or polar groups, and the binder preferably further includes a cement and cures by moisture.

19. Composite stone according to at least one of the preceding claims, characterized in that the binder (5) has a pasty consistency.

20. Composite stone according to at least one of the preceding claims, characterized in that the head surface (4) has a trough shape and the circumferential raised edge (11) has openings, preferably each

10 cm side surface of the support body (9) 1 to 3 spaced openings for the defined delivery of excess binder (5).

21. A method for producing composite molded blocks (1) having an upper plate (2) as a cover layer and a support body (3) produced by a molding process, having a head surface (4), the upper plate (2) and the support body (3) being over the The head surface (4) of the support body is permanently connected and the head surface (4) of the support body is trough-shaped for receiving the binder mass and the method comprises the following steps:

Placing concrete in a mold frame which corresponds to one or more of the support bodies to be produced,

- Trough-shaped contouring of the head surface (4) of the support body by means of a negative mold, the negative mold being a contoured stamp or a contoured base plate of the mold frame or by a milling process or

Drilling process possibly connected with the insertion of spacers, - Applying the pasty binder (5) to the top surface (4) of the support body (3), and

- Aligned and precisely fitting the top plate (2) and the support surface (13) formed by the head surface (4) of the support body.

22. A method for producing composite molded blocks according to claim 21, characterized in that a plurality of cavities (16, 17) extending in the direction of the base surface (7) are introduced by the stamp and / or by molding in the mold frame and these are preferably introduced by pins mounted on the stamp surface or by means of pulling or inserting devices on the stamp and / or mold frame can be introduced or produced.

23. A method for producing composite molded blocks according to claims 21 and 22, which means that a plurality of partial bearing surfaces (14) extending from the base surface (7) are introduced through cavities in the stamp surface.

24. The method for producing composite molded blocks according to at least one of claims 21 to 23, characterized in that the step of applying the paste-like binder to the head surface (4) of the support body by means of metering nozzles, in particular a slot nozzle, is flat, preferably in the form of flat strands, or defined points, in particular flat in the form of a cuboid, which has a height of 2 mm to 5 mm, in particular 2.5 mm to 3 mm, and / or the area all around the edge contact surfaces ( 15) is smaller than the head surface of the support body.

25. A process for the production of composite shaped blocks according to at least one of claims 21 to 24, characterized in that the step of applying the top plate (2) at least in the area of contact of the pasty binder with slight reciprocation along the axis of approach (vertical vibration movements) and, if necessary, additional horizontal vibration movements.

26. A method for producing composite molded blocks according to at least one of claims 21 to 25, characterized in that the step of applying the top plate (2) is carried out by a gripper, in particular a suction head gripper, which preferably additionally performs the functions of centering, vibrating with an adjustable force and / or pressing on with a defined adjustable force.

27. A method for producing composite molded blocks according to at least one of claims 21 to 26, characterized in that the top plate (2), binder composition and / or support body (3), also with regard to its top surface (6), according to one of claims 1 to 20 are defined.